warner robins air logistics center people first…mission always high velocity maintenance overview...

Warner Robins Air Logistics Center

People First…Mission Always

High Velocity Maintenance

Overview

Presented By:Jerry MobleyWR-ALC/HVM

June 2010


People First…Mission Always2

What is High Velocity Maintenance?

An AFMC-wide initiative to dramatically transform production operations in support of increasing aircraft availability, seeking to better emulate industry’s high daily rate of touch-labor maintenance

HVM examines all processes which impact aircraft programmed depot maintenance across the enterprise, including not only product flow, but also funding, requirements, infrastructure, materiel support, and information technology


People First…Mission Always 3

HVM Concept

Refine Scheduled Maintenance– Correct Inefficient Processes

• Low velocity compared to Industry»Airline burn rate 500-900 hours/day»ALC PDM 145-220 hours/day

– Implement Industry Best Practices• Daily Standard Work• Point-of-Use Task Kitting• Mechanic-Centric Focus

– Know tail number condition

Maintain Enterprise Approach• Scalable and Transportable Processes

Single Maintenance Concept

•1000

•500

•0

• Vel

oci

ty

(hrs

/day

)

•Industry Velocity

•PDM•ISO •ISO•HSC •ISO •Maintenance Cycle

•USAF Depot •Velocity

•Create an Ideal Process and Repeat it Every Time

HVM VISION

Increase Aircraft Availability using AFSO21 tools to establish a synchronized, integrated, end-to-end process such that maintenance does not impact mission requirements



Current State Limited Knowledge of Aircraft Condition

Two Mx systems; creates knowledge barriers 5+ Year PDM cycle (C-130)

Damage accumulates Promotes a “must fix now” mentality

Job Shop Environment Mechanic gets own tools; searches for parts;

accomplishes own set up Inadequate Planning – req’ts, Mx work, parts,

materiel, equipment Lacks information – complete BOM, planned

work, support Stove-piped Processes and Execution

Unsynchronized, inefficient, encourages work arounds (non-compliance)

Future State Known Aircraft/End Item Condition

Lead Time Ahead of Induction – Parts, Training, Infrastructure, Equipment, Data, etc.

Mechanic-Centric Focus (Surgeon) Parts, Tools, Data, Equipment Pre-Positioned

at Point of Use Maximum Use of Kitting

Expand Standard Work & Processes Choreograph Repair Operations Synchronize work Single Maintenance Concept Integrated Planning, Decision-making, & Data

Collection

Attributes



HVM Future State Process

Potential IFS Interfaces- IMDS/G081 (CAMS)- PDMSS- Concerto- MWR- AIRCAT- PM/CCAT- AFSAS- FEMS- IETMS- JEDMICS- CENTRA- Spreadsheet of Task Kit Configurations- AFMC Form 202 and TO 00-25-107 Engr Dispositions- DFIMS- DMAPS- JOPMS- MFT- MP&E- J025- BQ System (FIRST)- CAFDEx (CAM Process)- CEMS- Digital Data Exchange with DLA- CREPR- EXPRESS- ECSS- AMREP- BOM (G005M)- COLT- COPA

Industrial Engineer Liaison Engineer Planner

Cell HVM Team

Supportability(Task Kitting)

SupervisorScheduler Quality/Safety

Product Support Center Characterizes Issues

PSC Determines Scope of Resolution

Fix with Current PSC Resources

Cell Resolve Issue

YesNo

Pre-Dock Activities * De-Fuel * Inventory * Tailored Disassembly

TailoredEvaluation & Inspection

HVM Wing Cycle

HVM Fuselage Cycle

HVM Paint and Flight Controls

HVM Empennage Cycle

De-paint Remove &

Route Flight Controls

Paint

Ops Checks/FCF

Joint Acceptance/Sell

Paint Touch Ups

Inspect, Repair, Lube, & Dry Rig Flight Controls

Install & Rig Flight Controls

Fuselage structural inspection & repair

Install, rig & ops ck Landing Gear &

Brakes

Remove Gear, Perform wheel

well Refurb

Complete Wing structural inspection

& repair

Fuel System inspection &

repair

Empennage, Ramp, aft door, & 737 bulk head structural

inspection & repair

Remove Engines, inspect and

reinstall

Avionics & Electrical Systems inspection &

repair

Pressurization checks

D+0 Induct AircraftRequirements Review Board

(RRB)

Bill Of Work Process(BOW)

{Contains BOM}

Maintenance Requirements Supportability Review Panel

(MRSRP)

Feed Aircraft & Missiles Requirements

Document(AMRD) Process

Deliver Fully Supportable Standard Daily Work

Package to Production

CAM Office Loads Budget Authority

SPO/PM Initiates Quarterly Proj Order for

each MAJCOM

MXW/OB Accepts Quarterly Project Order

MXW/OB Establishes JON

Number for Tail Nr

MXW/OB Notifies Work Loader that Funds are

Available

MXW/OB Tracks Expenditure by Tail

Number

Budget Close Out

Requirement FeedbackConsumption Feedback

Aircraft Requires Over & Above FundingO/A Funding

Parts (DLA Retail Supply)Consumables and Depot Level Repairables

Gather E&I data for next cycle

Aircraft Maintenance Team (AMT)

UDLM/Mod

Product Team

Financial Team

Materiel Team

Requirements Team

Industrial Engineer Liaison Engineer Planner

Cell HVM Team



Product Support Center Characterizes Issues

PSC Determines Scope of Resolution

Fix with Current PSC Resources

Cell Resolve Issue

YesNo

World WideMaintenance and

OperationsData

Data collection and Analysis

- RCM Analysis (IRCMS)- CBM+ Predictive Tools- Engineers Tool Box (LCSE)- Modeling and Simulation of workflow (DELMIA)- Pre-induction Analysis Tools- Mx and Modification Schedule (IFS)

- IFS- AIRCAT

- Flight Data- Operating Locations- Field Level Engr Requests- ASIP Inspections- Center and Outer Wing Service Life

- Mx Field Data (IMDS)- Foreign Operator Data- PIWG/CPAB Action Items- DRs (G021 and JDRS)- Hazard Tracking DB- AFSAS- PDM Trends (IFS and 202 Data)- Specific Tail Number Mx Requests (AFTO Form 103)- MECSIP Requirements- Prop and Engine Change Reqts (CEMS)

Load Requirement into PDMSS/ECSS

Info/Tech Team

Pass changes in support equipment requirements to

AFFVESA

- CREPR- COLT- COPA

Specific Tail #Mx Request (was

AFTO 103)

Develop Standard Work/Kit

Daily Std Work Package (PDMSS/JST/ECSS)

PDMSS Data Dump to REMIS

·Supporting processes (requirements, budget, etc) optimized & integrated to support Mx activities

For Official Use Only

D+7Exception

ManagementProcess Begins

D+5Assessment

Complete

D+6Complete Release of Parts to CMXG

for Repair

Daily Task Requirements

DLA Collaborative Forecasting – Parts

(Digital Data Exchange)

AF Collaborative Forecasting – Parts, Materials, Tools, Equip

CONCERTO

Mx Work Request (MWR/ICARR/IETM)

Drawings and Standard Visual Work Tech Orders

(JEDMICS, CENTRA& IETMS)

CAFDEx/ECSS

Acft Schedule (PDMSS/ECSS)

Routed Item Tracking (AF-GET and ROCIT)

Supportability Data

Equipment Database (FEMS)

J025A Automated Project Order System

AMREP UpdateAMREP Update

BOM (G005M/IETM)

HVM ProcessVersion: 20 July 09

Visual Management of

Progress

Engineering Approval

Required?Yes

No

Begin Work at Risk?

Operation Previously

Developed?

Engr Supv Approval or

Update Solution

No

Work Request Received Through

IETM

Yes

Aircraft Maintenance Team Develops Solution

Load Operation in IFS Against Serial

Number

Update IETM with Final Configuration Data of Work

Performed

Yes

No

DMAPS, DFIMS & JOPMS

Time and AttendanceWork Certification

Aircraft Maintenance Team (AMT) Additional Workload Request Decision Process

Supportability Process(P001)

Additional Workload Request Process

Supportability Review Process

IETM(Parts Config)

Review Operations for

each Tail Number in PDMSS/ECSS

P001. Supportability Review Process

Required tools, parts, tech data, etc by operation number for next cycle on each aircraft

Supportable?

Safety of Flight?

Possible Work Around?

No

No

Yes

Accomplish Next Cycle

NoAF/DLA Expedite

Process

Load Requirement Into PDNSS/ECSS Against

Appropriate Cycle

Yes

YesFunding Approval Process

World Wide Intelligence Data

on Future Requirements

- Expected mission and operational requirements (impact to fatigue driven inspections)- Expected environmental impacts (corrosion, system and avionics impacts)- Surge Requirements- Modification Requirements

RFID Tags on aircraft, routed items, special tools and

support equipment

Operation Loaded in IETM

P003. Requirements Validation and Verification Process

Industrial Engineer Reviews Process

Val/Ver?

On Equipment Validation/Verification of New

Requirement Process

PDMSS/ECSS

Effectivity, Initial Reqt, Recurring Reqt

Update Requirement

Review Requirement

Detailed Requirement Draft in Standard

Visual Work Format

No

Yes

Resource Requirements

Special Tools

Hazmat/Pharmacy Items

Job Routed Items

Standard Visual Work Tech Data

MOD-DOCKPRE-DOCK

POST-DOCK

2

Industrial Engineer E & I Engineer IE Tech

Cell HVM Team



Aircraft Maintenance Team Characterizes Issues

AMT Determines Scope of Resolution Cell Resolve IssueYes

1 3

On Site Integrator

Tied to: • Operation Number

• Acft/Date/Time/Dock

Kit AssemblyJust-in-time

Pre-position at P.O.U.

Kit Component Aggregation

Pull

Fix with Current AMT Resources?

FOM – Facilitate Other Maintenance

MRSR PROCESS

Strategic Planning

NO

Corrective Action ProcessFlow/Disposition

Maintenance History &

Requirements

Supportability Review Process

(DLA Retail Supply)Consumables and Depot

Level Repairables

Special Tools

Hazmat/Pharmacy Items

RPC Items

Standard Tech Orders

Funding for Parts

Pre-Dock Activities * Wash * Inventory * Maintenance Safe * Tailored Disassembly

Post-Dock Activities * Fuel Work * Records Review * Flight Acceptance

Field HVM Plans &

ScheduleMaintenance

History & Requirements

HVM In The Field

Pre-Induction Inspection Prior to 1st

HVM Cycle

ACRONYMS

AF-GET Air Force-Global Enterprise TrackingAMREP Aircraft MisAMT Aircraft Maintenance TeamCENTRADFIMS Defense Industrial Financial Management SystemDMAPS Defense Maintenance Accounting and Production System FCF Functional Check FlightFEMS Facilities and Equipment Management SystemICARR Inspection Corrosion and Repair RecordingIE Industrial EngineerIETMS Interactive Electronic Technical Manual SystemJOPMS Job Order Production Master SystemMRSR Maintenance Requirement Supportability ReviewMWR Maintenance Work RequestROCIT

AMRD

Kit Warehouse

Kit Staging

Does Kit consist of

bulk or heavy items?

Coordinate

delivery of bulk

or heavy item

Deliver kit to POU,

scan to delivery

point

No

AMT

Provide list for kit delivery from Daily

Standard Work sequence (24 hrs in

advance)

Review additional resource needs and

drives change to BOM

Yes

Mechanic

begins task

Mechanic needs

additional

resources

Material handler delivers addition

al material

/ resourc

es

Work card

complete by end of

shift

No

Begin Deliver

y Proces

s

Receive

Delivery

Signal from AMT

Scan “Out for Delivery

”

Kit complete, ready

for delivery

AMT / Material handler reviews

need

Material handler obtains needed items from

integrator

warehouse

Mechanic

signals for

additional

resources/

completes

feedback card

Yes

Kit retrieva

l

Complete kit build

Pre-deliver

y validation OK

Yes

No

Mechanic

reviews kit for

completion

Accepts

Rejects

Yes

No

Kit Delivery Process

The asset is removed from the

aircraft

The asset is inspected by E&I personnel or a

mechanic

An inspection tag is attached to the

asset

The FLS attaches a barcode tag and all

the required paperwork to the

asset

The FLS scans the asset it into the PDMSS/ROCIT

database for tracking

Is the asset serviceable or unserviceable

The asset is taken to the Integrator’s

Kit Area(delivery scan)

Asset is delivered to appropriate support shop. Delivery scan accomplished

Asset processed in PDMSS/ROCIT

with EDD’s established

Repair actions accomplished

Serviceable

Un

serviceable

The asset is placed in a waiting area designated for unserviceable

assets

The asset is placed in a waiting area designated for serviceable

assets

Supply or Job Route item?

Job Route item

Unserviceable / Serviceable

Supply Warehouse

Supply item

Asset processed in PDMSS/ROCIT

closing repair and allow for pick-up

FOM asset incorporated into

kit and/or delivered with support materiel to mechanic

END

FOM Flow Process

Begin Kit Build

Standard and non-standard task list for BOW with

BOM provided by MRSR/AMT

Remove kit from build staging area

Generate task kit content list (BOM)

Gather required parts and

,reparables for the kit Visually inspect for

obvious damage, expiration date or

calibration requirements

Visual inspection

good

Return defective part, order/obtain

replacement

No

Place item in kit

Move kit to delivery staging

area

End process

Apply Tail Number(See Kit Label

Process Guide)

Apply security “seal”

Yes

Gather required Consumables

Gather required Tech Orders

Gather required Hazmat

Gather required PPE

(non-personal)

Gather required Tools

Gather required Specialty Tooling

Gather required Test Equipment

Gather required IPV

Gather Required(Expendables)

Blue Straw items

Document kit completion

In stock at Kitting

warehouse

Rep CON

No

Repairable Consumable

Yes

Initiate PQDR process

Kit Build-UpKit Design begins

Obtain contents listed on Daily Standard Visual Work card(parts, hardware,

tooling, consumables, hazmat, etc)

Contents includes large, bulk or FOM

parts

Includes tooling or special

tooling

Content includes test equipment

Contents exceeds 35 lbs

Contents fit on shadow board

Build Tub style kit No

Equipment dedicated to kit

Yes

Obtain test equipment from PSC

No

Kit ready for StagingDesign

multiple kits instead of

single

Yes

Tool dedicated to kit

Yes

Obtain tool from PSC

No

Kit contains PPE

Kit contains Hazmat

Yes Yes

NoNo

BuildShadow Board

BuildCustom Kitor establish coordinated

delivery

Yes

YesNo

Obtain PPE from PSC

No

Yes

YesObtain Hazmat

Return tools, test equipment, PPE

and Hazmat once design and layout

are complete

No

MRSR determines kit required to

support task or kit requires

modification

Document Kit has been designed for

correlated task

Document Kit Label

(See “Kit Label” in Process Guide)

No

Kit Design

Begin Retrograde

Remove highest priority kit from

rack

Process any remaining

HAZMAT in accordance with AF regulations

Kit contains HAZMAT

Kit contains Special tooling

Kit contains Repairable

Kit contains basic tooling

Turn parts in to Supply

Route Tooling back to PSC

Verify all tools remain

Remove and dispose of FODNo No

YesYesYes

NoScan materiel

usage

Return unused materiel to stock

Standard Build Kit

Yes No

YesNo

Return kit to staging area for

next kit buildEnd

AMT

Process kit content consumption for billing and material forecasting

Receive feedback on kit content and sequencing to Daily Standard Work

Drive modification to BOM, sequencing or kit if feedback is validated

Kit Retrograde

DLA provisioned consumables(Pre-defined by acquisition code or RPF%)

IPV

Unserviceable Job Routed Assets

Serviceable

HAZMAT

Consumables Sources of

Supply

Onsite CMXG / EMXG Back

Shops

Special Tooling / Special Test Equipment

Other supply points to the Integrator

Unserviceable Job Routed

Assets

Repair Services Source of Supply

HAZMAT Sources of Supply

Blue Straw / Expendables(Non aviation consumables)

Alternative Commercial Sourcing of Immediate Material Needs

Contracted Integrator provisioned consumables(Pre-defined by acquisition code or RPF%)

Stock Positioned Consumables

Kitting Materiel

Integrator’s Kitting Warehouse

Kit Design, Construction, Build-Up, Delivery, and Retrograde Process

100% DLA provisioned consumablesOR Consumable Supply Warehouse

Unserviceable / Serviceable

Supply Warehouse

Unserviceable Supply Assets

Unserviceable

MISTR at an offsite location Unserviceable Assets

Serviceable Assets

Serviceable

Supply Points

Pre Induction Inspection

107/103 Data

781 Data

Aircraft Tail Nr Cycle Work

Package

E&I Initiates MWRPlanner Reviews

MWRTrigger Card

Exists?Reject MWR

MWR Supportability

Review

Task Supportable in

this Cycle?

Yes

No

Yes Incorporate into Work Package and Execute

HVM Master Ops List

MRSR Disposition

No

In Work Spec?Yes Planner creates

MWR

No

PAO Approves Work

Yes

Submit Request for additional work

to PAO

No

Deferred Work

AMT Decision

AMT MWR Flow

PDMSS/Oracle CMRO

Visual Work Cards

Available?Yes

NoDevelop SVWCProcess PXXXIETM

MRSR develops fully supportable , sequenced, executable work package

4 Cycles – 18 Month Interval to integrate/replace current 15 Month Isochronal Inspection

Standard Work Cards drive out Process variability

Actual requirements drive material purchases rather than historical probability AMT provides

continuous real time support

Integrator delivers POU task kits to mechanic

Data analysis critical to defining requirement



HVM Future State“Swim Lane” View

6

HVM Process Map with Products25 May 2010

Exe

cute

th

e P

lan

De

velo

p S

up

po

rtS

et

the

R

eq

uir

em

en

t

Approved Additions, changes

or deletions to Tech Data

(Fully Defined Req’t)

Data Analysis Process

(RCM & Tail #)

Requirements Review Board

(RRB)

Data Collection Process

Recommended Changes to Tech

Data(Scheduled Mx Reqt)

“Good” Usable Data

MRSP-S Bill of Work (BOW)

MRS Review

DistributedDaily Visual Work Cards (DVWCs)

FullySupportable Tail #

Bill of Work (BOW) Including:DVWCs, Sequenced & man-

loaded, Kit Requirements List,

Aircraft Maintenance support Team

(AMsT)

Product and / or

Data

Task Kitting Process

Repaired Aircraft

Aircraft in need of repair

Production CellPoint of Use

Task Kits

Requirements Process

Materiel ProcessProduction

Process

Maintenance Requirements Supportability

Process – Tactical (MRSR-T)

Tail # BOW changes

Aircraft & Missiles Requirements

Document (AMRD) Process

MRSP-S Supportability

MDSBill of Work

SupportableMDS #

Bill of Work

MRSP-O Materiel Planning

Aircraft Condition Data Generation &

BOW feedback(inc PII)

New Reqt?

Y

N

Fleet Mgt & Aircraft Scheduling

Aircraft Induction Schedule

Data Collection Process

(Start Process over again)

Supportable?

Baseline

MRSP-O - Tail # Bill of Work (BOW)(Including review)

ApprovedSupportable

Tail # Bill of Work

Y

Defines Right Requirement

Builds Daily Std Work Package-Accomplishes supportability-Tailors package to tail number- Defines sequence -Feed Financial process

Executes tailored work packagePoint of Use Task KitsMan-loads a/c- High Burn Rate



• PDM & ISO not synchronized

• PDM scheduled every 5-6 yrs

Cycle 1 HSC

•1000

•0• Vel

ocity

(hr

s/da

y)

•500

HVM State

HSC HSCCycle 2 Cycle 3 Cycle 4

•ISO •HSC•ISO •HSC •ISO•HSC•ISO

•1000

•0

•500

• 145-220 hrs/day

• 160 Flow Days

Current State

• Vel

ocity

(hr

s/da

y)

• Goal: 500 + hrs/day

High Velocity Maintenance Life Cycle Comparison

• Integrated Scheduled Mx (PDM & ISO)• High velocity, multiple cycles over 5-6 yrs

Improved AA

Less A/C on ground

Reduced O&S Cost

Efficient MX Process

•C-130

•18 month interval

7



Implementation StrategyConcept development: Summer 07 – Spring 08Process development: Spring 2009

Creation of daily standard work: Ongoing Creating supporting data: Ongoing

Process validation: Summer 2009-Spring 2011 9 validations

Pilot Program: Fall 2011-2012 AFSOC C-130 aircraft: 18 – 21 months post PDM

Fleet-wide deployment: 2013+ Remaining C-130 fleet transitioned by MAJCOM

C

HVM Concept Development

Process Validation & Demonstration Production & Deployment Operations & Support

HVM HPT Charter

HVM Process Development

Aircraft Induction Readiness Review

A B

AFSOC ImplementationFleet Implementation

Val #1 Val #2

8

Val #3Val #4 Val #5


People First…Mission Always9

Benefits of SLIM to HVM

AircraftAvailability

HVM

ECSSCAMGLSC

PLM

AAIP

HVM for PDM/ISO

WR-ALC C-130 Prototype

Optimizes the PDM process (the “how”)

Includes all supporting processes

Optim

ize the field/depot

requirements

(the “what, w

hen and where”)

Expands HVM to be “scalable and transportable”

Ove

rarc

hing

ent

erpr

ise

initi

ativ

es

Std Work Supply Chain Ops Lifecycle Mgmt Sourcing Tech Development

RCM

CBM+

MSG-3

IntegrityPrograms

SLIM

•SLIM focuses on overall weapon system performance assessments•Efficient & effective data collection and analysis•Proactive action using the analysis results•Integrating CBM+, RAM, RCM/MSG-3, WSIP, MFOQA, and EAVI efforts

Benefits Enables Optimized MX RequirementsFacilitates increased knowledge of aircraft condition



Discussion/Questions

High Velocity Maintenance



HVM & MSG Relationship

HVM defines the “How” maintenance is accomplished• Optimizes Maintenance processes – “Mechanic Centric Focus”

–Establishes processes to achieve “high daily touch labor rates” through detailed advanced planning with supportability; choreographed, synchronized work packages; aircraft man-loading; implementation of daily standard work; pre-positioned point-of-use task kits –Moves toward single “Maintenance System”

• Incorporates ISO’s (C-130)

MSG-3: Defines the “What” needs to be done • Established the appropriate inspections and optimum interval for

accomplishing the inspections–Ensures you accomplish the “Right “ maintenance at the “Right” time.

11

The optimum MX solution would employ the MSG-3 methodology as the foundation for HVM processes to be applied to achieve the most

effective scheduled maintenance program



HVM & SLIM

12

High Velocity Maintenance-Improving “How Mx is Done” – standard processes and synchronized to optimize flow time- Pre-planned support, Point of Use task kitting, mechanic centric focus to increase velocity

MSG-3- Overall system level approach- Hierarchical zonal inspections- Structures: Logical process for determining Mx requirements

- Safe life vs Damage Tolerant- Accidental, Environmental or Fatigue Damage Considerations

- Mechanical Systems/Engines - Uses RCM Approach

Maintenance ta

sks a

nd interva

ls

ASIP- Inspection Reqts for tracked zones

CBM+ What- Diagnostics- Prognostics- Data Analysis- RCM

CBM- Real-time assessment of condition - Embedded sensors - External tests and measurements - Maintenance only upon evidence of need

CBM+ How- Interactive Training- Portable Maintenance Aids- Interactive Electronic Technical Manuals- Integrated Information Systems- Automatic Identification Technology

What Maintenance to Perform

Feedback How Maintenance is Performed

RCM- Assess system functionality - Identify failure modes and effects- Determines consequence of failure - Logical process to determine actions and insure mission success

Feedback

warner robins air logistics center people first…mission always high velocity maintenance overview...

Documents

standard work processes

mx work

depot maintenance

planned work

labor maintenance hvm

standard work point

executable work package

hvm concept